Epoxy resin composition and construction material containing the same for use in new construction or for repairs

Abstract

An epoxy resin composition is provided consisting essentially of (a) an epoxy compound having at least two epoxy groups in each of its molecules, (b) an ester of a mercaptoalkylcarboxylic acid having on an average more than two thiol groups in each of its molecules and in which the number of carbon atoms of the alkylene groups between the ester groups and the thiol groups is in excess of one on an average, and (c) a tertiary amine-type curing accelerator. This resin composition is used for new construction or repairs either as such or in the form of a construction material obtained by mixing this composition with aggregates and optionally with additives.

What is claimed is: 
     
       1. A construction material for use in new constructions or for repairs comprising [A] an epoxy resin composition consisting essentially of (a) an epoxy compound having on an average at least two epoxy groups in each of its molecules, (b) an ester of a mercaptoalkylcarboxylic acid having on an average more than two thiol groups in each of its molecules and in which the number of carbon atoms of the alkylene group between the ester groups and the thiol groups is on an average in excess of one, and (c) a tertiary amine-type curing accelerator;   [B] at least one aggregate selected from the group consisting of (d) natural and artificial coarse aggregates having a particle diameter of 2.5 to 50 millimeters, and (e) natural and artificial fine aggregates having a particle diameter of less than 2.5 millimeters, and, as required,   [C] an additive that reduces the viscosity as well as functions as an extender.   
     
     
       2. A construction material according to claim 1 wherein the said epoxy compound (a) is a bisphenol A-type epoxy resin. 
     
     
       3. A construction material according to claim 1 wherein the said epoxy compound (a) is a novolak-type epoxy resin. 
     
     
       4. A construction material according to claim 1 wherein the said mercaptoalkylcarboxylic acid ester compound (b) is a thiol compound obtained by esterification between polyol and mercaptoalkylcarboxylic acid. 
     
     
       5. A construction material according to claim 1 wherein the said mercaptoalkylcarboxylic acid ester compound (b) is a compound obtained by esterification between a compound having on an average in excess of two epoxy groups in each of its molecules and a mercaptoalkylcarboxylic acid. 
     
     
       6. A construction material according to claim 1 wherein the said mercaptoalkylcarboxylic acid ester compound (b) is a thiol compound obtained by esterification between a compound having on an average more than two epoxy groups in each of its molecules and mercaptoalkylcarboxylic acid of the general formula   HS--C.sub.n H.sub.2n --CO.sub.2 H                          [I]     wherein n is a rational number having on an average a value of 1<n≦3.   
     
     
       7. A construction material according to claim 6 wherein n is a rational number of from 1.5 to 2.5. 
     
     
       8. A construction material according to claim 1 wherein in the epoxy resin composition the components (a) epoxy compound and (b) ester of a mercaptoalkylcarboxylic acid are mixed at a ratio such that the epoxy equivalent weight number of component (a) to the theoretical active hydrogen equivalent weight number of component (b) is in the range of from 0.5 to 2, and the amount of (c) tertiary amine-type curing accelerator is up to 15 percent based on the total weight of the epoxy resin composition. 
     
     
       9. A construction material according to claim 1 wherein in the epoxy resin composition the components (a) epoxy compound and (b) ester of a mercaptoalkylcarboxylic acid are mixed at a ratio such that the epoxy equivalent weight number of component (a) to the theoretical active hydrogen equivalent weight number of component (b) is in the range of from 0.8 to 1.2, and the amount of (c) tertiary amine-type curing accelerator is from 1 to 10 percent based on the total weight of the epoxy resin composition. 
     
     
       10. A construction material according to claim 1 which comprises from 1 to 50 percent by weight of the epoxy resin composition. 
     
     
       11. A construction material according to claim 1 which comprises from about 3 to 25 percent by weight of the epoxy resin composition. 
     
     
       12. The construction material according to claim 1 wherein the mercaptoalkylcarboxylic acid ester (b) is a trimethylolpropane-mercaptopropionic acid ester, a trimethylolpropane-mercaptopropionic acid-thioglycollic acid ester, a pentarerythritol-ethylene glycol-mercaptopropionic acid ester, or a trimethylolpropane-propylene glycol-mercaptopropionic acid-thioglycollic acid ester. 
     
     
       13. A construction material according to claim 12 which comprises about 7.5 percent of the epoxy resin composition as a binder and about 92.5 percent of an aggregate mixture of said coarse aggreates (d) and fine aggregates (e) at a weight ratio of (d): (e) of about 7:3. 
     
     
       14. A construction material according to claim 1 which comprises a mixture of about 100 parts by weight of the epoxy resin composition as a binder and about 100 parts of natural sand having a particle diameter of less than 2.5 mm. 
     
     
       15. A construction material according to claim 1 which comprises about 25 parts of the epoxy resin composition as a binder and about 75 parts by weight of natural sand having a particle diameter of less than 2.5 mm. 
     
     
       16. A construction material according to claim 1 which comprises about 3 parts by weight of the epoxy resin composition as a binder and about 97 parts of natural aggregates having a particle diameter of from 13 to 5 mm.